The document outlines the principles, history, and implementation of the 5S methodology for workplace organization, which includes sorting, systemizing, sanitizing, standardizing, and sustaining. It emphasizes the benefits of 5S in improving efficiency, safety, and workplace culture while providing a structured approach for effective implementation. Participants will learn to understand and apply 5S principles to enhance productivity in their organizations.

1. 5S Awareness & Implementation

2. 5S Awareness & Implementation
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•Name
•Designation
•Experience in 5S

3. 5S Awareness & Implementation
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 Course Outline
1. Introduction to 5S History , Concepts, Benefits
2. Application of 5S
- Seiri (Sort/Structurize)
- Seiton (Set-in-Order/Systemize)
- Seiso (Shine/Sanitize)
- Seiketsu (Standardize)
- Shitsuke (Sustain/Self-Discipline)
3. Tips, Implementation , Examples
4. Practical

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 Course Objectives
At the end of this course, participants will be able to:
• Understand the principles of 5S
• Understand benefits of using 5S & workplace
efficiency
• Implement 5S & maintain it in any organization
• Develop self-directed staff using team-focused
approach.

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 History & Origin
• Henry Ford first perfected flow
production in the early part of
the 20th Century.
• Toyota improved Ford’s design
in the 30s and 40s developing
its LEAN production system to
be more adaptive to needs and
changes.
• It is based on “order &
structure”
• It was required to ensure the
sustainability of the “Visual
Factory” concept.
• Taiichi Ohno created the original
“4S” concept of workplace
organization and visual control at
Toyota during the early 1950’s.
• The concept was further refined
into “5S” during the 1960’s and
1970’s.
• U.S. manufacturers added a sixth
“S” for “safety” during the 1990’s.
• The 5S+1 tools were recently
modified by Gwendolyn Galsworth
to include “Visual Workplace”
disciplines.

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Basic Concept: What is 5S?
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 What is 5S? Basic Concept
• 5S is a workplace organization technique
• It is a way to involve associates in the ownership of
their workspace
• It helps create and maintain the efficiency and
effectiveness of a work area
A system to reduce waste and
optimize productivity

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 What is 5S? Basic Concept. How??
• Maintaining organized work area
• Using visual management

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Seiri Seiton Seiso
Seiketsu Shitsuke

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Sort /
Structurize
Set-in-Order
/
Systematize
Shine /
Sanitize
Standardize
Sustain /
Self-
Discipline

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Sisih Susun Sapu
Seragam
Sentiasa
amal

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 Seiri (Sort / Structurize / Sisih)
 Separating the Needed from the Not-Needed
 Eliminate not-needed items and perform an initial
cleaning
 Establish criteria/handling of items
 Identify not-needed items
 Move not-needed items to holding area
 Conduct a white-elephant sale
 Conduct an initial cleaning

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 Seiton (Systemize / Set in Order / Susun)
 A place for everything and everything in its place,
clean and ready to use
 Arrange workplace for safety and efficiency
 Identify key equipment and supplies
 Determine location for each item
 Outline locations and zones
 Develop shadow boards, label items
 Document layout, equipment, supplies

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 Seiso (Shine / Sanitize / Sapu)
 Cleaning for Inspection
 Perform daily cleaning and inspection to understand work
conditions
 Identify points to check for performance
 Determine acceptable performance
 Determine visual indicators/controls
 Mark equipment/controls
 Conduct daily cleaning/inspections

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 Seiketsu (Standardize / Seragam)
 Developing common methods for consistency
 Make abnormal conditions noticeable and document
agreements
 Document agreements and checks
 Establish/document standard methods across similar
work areas
 Document new standard methods

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 Shitsuke (Sustain / Sentiasa Amal)
 Holding the Gains and Improving
 Maintain the gains from other 5S activities and improve
 Determine 5S Level of Achievement
 Perform routine checks
 Analyze results of routine checks
 Measure progress and plan for continuous
improvement
 Training & communication to all employees to ensure 5S
application – developing good habit to all employees.

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 Summary
 5S is a continuous program focuses on organization,
cleanliness, and standardization to improve profitability,
efficiency, service and safety

18. 5S Awareness & Implementation
Benefits
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 Safety
 Organized & clean- easy to spot hazards
 Visual indicators alarm people of hazardous situations
 Healthier workplace
 Quality Improvement
 Reduce contamination / deterioration
 No short cuts - right tools available
 Visual management - easy detection
 Not cluttered - minimize damage
 Improving Process Efficiency
 Items for work are easily located,
 Don’t waste time searching,
 Improve work flow

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 Reduce Cost
 Efficient use of space, reduce footage
 Reduce downtime
 Damage prevention
 Waste reduction
 Employee Motivation
 Organized & clean workplace,
 Availability of tools,
 Helps workers do job well
 Pride & ownership
 Improve work culture
 Positive image to customers

21. 5S Awareness & Implementation
Key for Success
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 Management’s visual commitment & example
 Employees
 Active 5S champions & committee
 Training, education, promotion
 Communication
 Plan & do, review & action
 Recognition & reward
 Part of daily operation plan
 Immediate feedback
 Challenge the situation
 No shame & blame

23. 5S Awareness & Implementation
Implementation
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24. 5S Implementation
Sort / Structurize / Sisih

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 Objectives
 Making work area organized
 Free up space
 Easy to FIND the things you need

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Set up Steering Committee
(Sponsor ,Chairman)
Plan schedule
budget &
programme
Define boundaries of
layouts, Area champions
or Owner
Communication &
Publicity,
Awareness & Training
Assign Steering
committee member to
1 or more areas
Optional:
Temp Red Tag Area

27. Area 1 Area 2
Area 3 Area 4
5S Awareness & Implementation
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Select zone
Involve the
workers &
supervision of
area
Move items
to temp red
tag area
RED TAG it
& Fill Log
Identify unwanted
or misplaced or
unknown items or
not used daily
Take before
picture
Take
picture
Evaluation

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RED TAG
Date
Name Signature
Item
Action required

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 Evaluation for Disposition
 Return to home
 Find a home for it
 Scrap it ( sell or throw )
 Recycle, reuse, rework, repair
Who
decides?

31. 5S Implementation
Set in Order / Systemize

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 Physical lines on the floor to identify
work areas, storage areas, finished product
areas, etc
 Put shadows on tools boards, making it easy to
quickly see where each tools belongs
 Provide shelves, cabinets, tool trolleys
 Label name of items for easy identification
 Provide location map

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35. 5S Awareness & Implementation
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36. 5S Awareness & Implementation
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Before After

37. 5S Implementation
Shine / Sanitize / Sapu

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 Do a one time clean up – floors, machines, shelves,
tools, storage boxes (repaint ,replace, refurbish if
necessary)
 Identify & report specific source of dirt, filth, leak, spill.
Eliminate it!
 Identify & report damages, broken parts, rusted supports,
racings, exposed wires, missing nuts & bolts expired
item, potential hazards and problems

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 Create a spotless workplace
 Identify and eliminate causes of dirt and grime –
remove the need to clean
 Sweep, dust, polish and paint
 Divide areas into zones
 Define responsibilities for cleaning
 Tools and equipment must be owned by an
individual
 Focus on removing the need to clean

41. 5S Implementation
Standardize - Develop process structure to support new
practices

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 Generate a maintenance system for the first three
 Develop procedures, schedules, practices
 Continue to assess the use and disposal of items
 Regularly audit using checklists and measures of
housekeeping
 Real challenge is to keep it clean

43. 5S Implementation
Sustain - Holding the Gains and Improving

44. 5S Awareness & Implementation
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 Means inoculate courtesy & good habits
 Driving force behind all 5S
 Deming’s point number 1: Constancy of purpose
 Make it a way of life
 Part of health and safety
 Involve the whole workforce*
 Develop and keep good habits
 Requires discipline & effort
 Carrot versus stick, Motivation & competition
 Train & coach
 Resources
 Audits
 Improve
 Communication board

45. 5S Implementation
Examples

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49. 5S Awareness & Implementation
Kick Start Exercise on Actual Worksite
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